Flexible circuit board and an electronic vaporizing inhaler comprising a flexible circuit board

ABSTRACT

A flexible circuit board comprises an elongate strip of flexible material having electricity conducting circuitry disposed therein or thereon. A first flap of material is disposed generally transversely to the first end of the elongate strip, where the first flap supports an inner electrode disposed over a center portion of the first flap and an outer electrode disposed around a perimeter of the first flap. Both the inner electrode and the outer electrodes are in electrical communication with the circuitry. A second flap of material is disposed generally transversely to the second end of the elongate strip, where the second flap supports a microprocessor in electrical communication with the circuitry. A first electrical lead is disposed on the elongate strip near the first end and a second electrical lead is disposed on the elongate strip near the second end. The first electrical lead electrically communicates with one of the inner electrode and the outer electrode, and the second electrical lead communicates with the other of the inner electrode and the outer electrode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a CONTINUATION of U.S. patent application Ser. No.15/038,455, filed on May 21, 2016, which is a National Stage Entry ofPCT/US2014/066949, filed on Nov. 21, 2014, which claims the benefit ofpriority to U.S. Provisional Patent Application No. 61/906,928, filed onNov. 21, 2013, and to U.S. Provisional Patent Application No.62/067,762, filed on Oct. 23, 2014.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention is directed to an electronic cigarette that providesconsistent dosage and that is better able to withstand drops and othermechanical shocks during assembly and use.

2. Background of the Invention

Electronic cigarettes are becoming popular among smokers who wish tosatisfy a nicotine craving but who also want to avoid the tar and otherharsh chemicals associated with traditional cigarettes. Electroniccigarettes contain liquid nicotine, which is typically a mixture ofnicotine oil, a solvent (such as propylene glycol, vegetable glycerin,or a combination of both), water, and sometimes flavoring. When the userdraws, or inhales, on the electronic cigarette, the liquid nicotine isdrawn into a vaporizer where it is heated into a vapor. As the userdraws on the electronic cigarette, he or she inhales the vaporcontaining the nicotine.

Electronic cigarettes and other vapor inhalers typically have similardesigns. Most feature a liquid nicotine reservoir with an interiormembrane, such as a sponge, fabric wadding (typically cotton), or otherfibrous material, that holds the liquid nicotine so as to preventleaking from the reservoir. Nevertheless, these cigarettes are stillprone to leaking because there is no impediment to prevent the liquidfrom flowing out of the membrane and into the mouthpiece. A leakingelectronic cigarette is problematic for several reasons. First, theliquid can leak into the electronic componentry, which can causeimpaired performance of the device. Second, leaks waste the liquidnicotine mixture. Finally, the liquid can leak into the electroniccigarette mouthpiece, and the user may inhale the unvaporized liquid,which provides an unsatisfying vaping experience.

Electronic cigarettes are also known to provide inconsistent dosesbetween draws. The aforementioned leaking is one cause of inconsistentdoses because the membrane may be oversaturated or undersaturated nearthe vaporizer. If the membrane is oversaturated, then the user mayexperience a stronger than desired dose of vapor, and if the membrane isundersaturated, then the user may experience a weaker than desired doseof vapor. Additionally, small changes in the strength of the user's drawmay provide stronger or weaker doses. Inconsistent dosing, along withleaking, can lead to faster consumption of the vaping liquid.

Additionally, conventional electronic cigarettes are often unreliable inthat the electronic components fail when the electronic cigarette isdropped or subjected to other mechanical shock. Conventional electroniccigarettes have multiple wires that run between various components andthat are held in electrical communication with solder joints. The solderjoints are prone to break, which can prevent the electronic cigarettefrom functioning to its full capacity if any function is even possible.Typically, electronic cigarettes are assembled by hand which increasesthe possibility for poor soldering. Moreover, when the electroniccigarette is assembled, the wires are stuffed into the housing in anyway that they will fit. This can cause stress on the solder joints,leading to breaks.

Conventional electronic cigarettes also predominantly use nichromeheating elements. Nichrome is an alloy primarily consisting nickel andchromium, and it is used in many electric heater applications. However,nichrome can reach temperatures as high as 900° C. very quickly, whichpresents several issues for a consumer product. First, some of thechromium may leach out of the heating element and be inhaled by theuser. Second, the high temperature of the heating element is dangerousto the user. Third, the heating element can burn the vaping fluid, whichnot only causes a poor taste but also can degrade certain chemicals inthe vaping liquid. Finally, by operating at such a high temperature, theelectronic cigarette will consume more energy, resulting in shorterbattery life.

Thus a need exists in the art for an electronic cigarette that is betterable to withstand leaks and occasional drops or other mishandling andthat provides consistent dosing.

SUMMARY OF THE INVENTION

An object of the present invention is to improve upon the deficienciesof conventional electronic cigarettes and other electronic vaporizinginhalers.

Another object of the present invention is to provide an electronicvaporizing inhaler that has improved resistance to leaks. A feature ofthe present invention is that the liquid to be vaporized is distributedthrough a series of capillaries that are able to contain the vapingliquid based on the surface tension of the liquid and that allows flowof the vaping liquid in response to small changes in pressure. Anadvantage of the present invention is that the liquid to be vaporizedonly flows through the capillary when the user draws on the electroniccigarette.

Another object of the present invention is to provide an electronicvaporizing inhaler in which the dose of vaporized liquid is consistent.A feature of the present invention is that the liquid reservoirdispenses the vaping liquid using capillary action. An additionalfeature of the present invention is that the microprocessor has a timerthat shuts off the heating element after a preprogrammed time in orderto avoid a large dose of vaping liquid. An advantage of the presentinvention is that the user receives a consistent dose of vaporizedliquid with each and every draw.

A further object of the present invention is to provide an electronicvaporizing inhaler with reliable parts. A feature of the presentinvention is that the components of the cigarette are joined usingsolder-less connections and electrical communication between componentsis made using foils instead of wires. An advantage of the presentinvention is that the electronic cigarette is better able to withstanddrops and other accidents.

Yet another object of the present invention is to provide an electronicvaporizing inhaler that has customizable dosing. A feature of oneembodiment of the present invention is that customizable doses can beprovided using a microprocessor that controls a heat pump. A feature ofanother embodiment of the present invention is that customizable dosesare delivered using a microprocessor that controls a diaphragm pump. Anadvantage of the present invention is that the user can select the usercan adjust the dose of vaping liquid delivered in a single puff or overthe course of a day.

The present invention provides An electronic vaporizing inhaler, saidelectronic vaporizing inhaler comprising: an electrical storage device;a liquid reservoir adapted to receive vaping liquid; a vaporizer,comprising: a substrate defined by a plurality of capillary apertures,wherein the capillary apertures provide fluid communication between thevaporizer and the liquid reservoir; a sponge in physical contact withthe substrate; a wick in physical contact with the sponge; and a heatingelement proximal to the wick; a microprocessor in electricalcommunication with the electrical storage device, wherein themicroprocessor is configured to direct current from the electricalstorage device to the heating element in the vaporizer; a sensorconfigured to detect when a user draws on the electronic cigarette,wherein the sensor is in electrical communication with themicroprocessor and wherein the sensor activates the microprocessor whenit detects that a user has drawn on the electronic cigarette; a housinghaving a first end and a second end, wherein the housing is designed tocontain the electrical storage device, vaporizer, microprocessor,sensor, and liquid reservoir and wherein the second end of the housingis a mouthpiece from which a user can inhale vapor from the vaporizer.

The present invention also provides an electronic vaporizing inhaler,said electronic vaporizing inhaler comprising: an electrical storagedevice; a liquid reservoir adapted to receive vaping liquid; avaporizer, comprising: a heating chamber, comprising: a substrate havinga plurality of apertures, wherein the plurality of apertures providefluid communication between the vaporizer and the liquid reservoir; afirst heating element, wherein the first heating element heats thevaping liquid to a temperature sufficient to create and burst a vaporbubble; a superior end having a plurality of nozzles, wherein the nozzleejects the vaping liquid when the vapor bubble bursts; a second heatingelement proximal to the nozzle; a microprocessor in electricalcommunication with the electrical storage device, wherein themicroprocessor is configured to direct current from the electricalstorage device to the first and second heating elements in thevaporizer; a sensor configured to detect when a user draws on theelectronic cigarette, wherein the sensor is in electrical communicationwith the microprocessor and wherein the sensor activates themicroprocessor when it detects that a user has drawn on the electroniccigarette; a housing having a first end and a second end, wherein thehousing is designed to contain the electrical storage device, vaporizer,microprocessor, sensor, and liquid reservoir and wherein the second endof the housing is a mouthpiece from which a user can inhale vapor fromthe vaporizer.

Additionally, the present invention provides an electronic vaporizinginhaler, said electronic vaporizing inhaler comprising: an electricalstorage device; a liquid reservoir adapted to receive vaping liquid; avaporizer, comprising: a primer chamber, comprising: an inferior endhaving a plurality of apertures, wherein the plurality of aperturesprovide fluid communication between the vaporizer and the liquidreservoir; a substrate embedded with a plurality of diaphragm pumps,each diaphragm pump comprising a diaphragm and a piezoelectrictransducer, wherein the each diaphragm flexes inwardly and outwardly inresponse to its corresponding piezoelectric transducer; and a superiorend having a plurality of nozzles, wherein each nozzle ejects the vapingliquid when its corresponding diaphragm flexes inwardly; a heatingelement proximal to the nozzle; a microprocessor in electricalcommunication with the electrical storage device, wherein themicroprocessor is configured to direct current from the electricalstorage device to the heating element in the vaporizer and to thepiezoelectric transducer; a sensor configured to detect when a userdraws on the electronic cigarette, wherein the sensor is in electricalcommunication with the microprocessor and wherein the sensor activatesthe microprocessor when it detects that a user has drawn on theelectronic cigarette; a housing having a first end and a second end,wherein the housing is designed to contain the electrical storagedevice, vaporizer, microprocessor, sensor, and liquid reservoir andwherein the second end of the housing is a mouthpiece from which a usercan inhale vapor from the vaporizer.

According to one aspect of the invention, a flexible circuit boardcomprises an elongate strip of flexible material having electricityconducting circuitry disposed therein or thereon. A first flap ofmaterial is disposed generally transversely to the first end of theelongate strip, where the first flap supports an inner electrodedisposed over a center portion of the first flap and an outer electrodedisposed around a perimeter of the first flap. Both the inner electrodeand the outer electrodes are in electrical communication with thecircuitry. A second flap of material is disposed generally transverselyto the second end of the elongate strip, where the second flap supportsa microprocessor in electrical communication with the circuitry. A firstelectrical lead is disposed on the elongate strip near the first end anda second electrical lead is disposed on the elongate strip near thesecond end. The first electrical lead electrically communicates with oneof the inner electrode and the outer electrode, and the secondelectrical lead communicates with the other of the inner electrode andthe outer electrode.

According to another aspect of the invention, an electronic vaporizinginhaler comprises an electrical storage device, a liquid reservoiradapted to receive vaping liquid, and a vaporizer. The electricalstorage device is disposed in electrical communication with a flexiblecircuit board.

According to a further aspect of the invention, an electronic vaporizinginhaler comprises an electrical storage device, a liquid reservoiradapted to receive vaping liquid, and a vaporizer. The electricalstorage device is disposed in electrical communication with a flexiblecircuit board having a first end flap disposed in electricalcommunication with a microprocessor and a second end flap having aninner electrode and an outer electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention together with the above and other objects and advantageswill be best understood from the following detailed description of thepreferred embodiment of the invention shown in the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of an electronic cigarette embodiment ofthe present invention;

FIG. 2 is a perspective view of the components of the electroniccigarette embodiment absent the housing;

FIGS. 3A-C depict various views of the flexible circuit;

FIG. 4 depicts the microprocessor of the invented electronic cigarette;

FIG. 5 depicts the vaporizer and liquid reservoir of the inventedelectronic cigarette;

FIG. 6 depicts a perspective view of the reservoir cap;

FIG. 7A depicts a perspective view of the vaporizer of the inventedelectronic cigarette;

FIG. 7B depicts a sectional view of the vaporizer depicted in FIG. 7Ataken along line 7B-7B;

FIG. 8 depicts a reusable embodiment of the presently inventedelectronic cigarette;

FIG. 9 depicts a sectional view of the reversible joint of the reusableembodiment;

FIG. 10 depicts an exploded view of the components providing electricalcommunication between the two portions of the reusable embodiment;

FIG. 11 depicts the cap region of the dosage control embodiment;

FIG. 12 depicts the heat pump variety of the dosage control embodiment;and

FIG. 13A-B depicts the diaphragm pump variety of the dosage controlembodiment.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing summary, as well as the following detailed description ofcertain embodiments of the present invention, will be better understoodwhen read in conjunction with the appended drawings.

As used herein, an element recited in the singular and preceded with theword “a” or “an” should be understood as not excluding plural of saidelements, unless such exclusion is explicitly stated. Furthermore, thereferences to “one embodiment” of the present invention are not intendedto be interpreted as excluding the existence of additional embodimentsthat also incorporate the recited features. Moreover, unless explicitlystated to the contrary, embodiments “comprising” or “having” an elementor a plurality of elements having a particular property may includeadditional such elements not having that property.

The present invention is directed to an electronic vaporizing inhaler.One specific embodiment of the electronic vaporizing inhaler is anelectronic cigarette. The description of the invention and accompanyingfigures will be directed to the electronic cigarette embodiment;however, other embodiments are envisioned, such as a vaporizer forhookah, flavored liquids, medicine, and herbal supplements.Additionally, the device can be packaged to look like an object otherthan a cigarette. For instance, the device could resemble anothersmoking instrument, such as a pipe, water pipe, or slide, or the devicecould resemble another non-smoking related object.

Mesh Membrane Embodiment

Electronic cigarettes are either disposable or reusable. The term“reusable” as used herein implies that the energy storage device isrechargeable or replaceable or that the vaping liquid is able to bereplenished either through refilling or through replacement of thevaping liquid cartridge. Alternatively, in some embodiments reusableelectronic device is both rechargeable and the liquid can bereplenished. A disposable embodiment will be described first, followedby a description of a reusable embodiment.

FIG. 1 depicts a disposable electronic cigarette embodiment 10 of theinvented electronic vaporizing inhaler. As can be seen in FIG. 1, theelectronic cigarette 10 has a cylindrical body with a relatively longlength “L” as compared to the diameter “D.” In terms of shape andappearance, the electronic cigarette 10 is designed to mimic the look ofa typical cigarette. For instance, the electronic cigarette can featurea first portion 15 that primarily simulates the tobacco rod portion of acigarette and a second portion 20 that primarily simulates a filter. Inthe disposable embodiment of the invented device, the first portion andsecond portion are regions of a single, non-separable device. Thedesignation of a first portion and a second portion is used toconveniently differentiate the components that are primarily containedin each portion.

As can be seen in FIG. 2, the first portion 15 contains the power andcontrol components. An electrical storage device 25 powers theelectronic cigarette 10. The electrical storage device 25 can be abattery, including but not limited to a lithium-ion, alkaline,zinc-carbon, nickel-metal hydride, or nickel-cadmium battery; a supercapacitor; or a combination thereof. In the disposable embodiment, theelectrical storage device 25 is not rechargeable, but, in the reusableembodiment, the electrical storage device 25 would be selected for itsability to recharge. In the disposable embodiment, the electricalstorage device 25 is primarily selected to deliver a constant voltageover the life of the device. Otherwise, the performance of theelectronic cigarette would degrade over time. Preferred electricalstorage devices that are able to provide a consistent voltage outputover the life of the device include lithium-ion and lithium polymerbatteries.

The electrical storage device 25 is in electrical communication with aflexible circuit board 40. Electrical communication between the variouscomponents of the electronic cigarette 10 is preferably made using aflexible circuit boards 40 or through direct electrical contact. Usingflexible circuits 40 instead of soldered wire connections improves thereliability of the device. Soldered connections are known to break whenthe device containing them is subject to mechanical shock, such as froma drop. When the soldered connection breaks, operation of the devicewill be impaired if it operates at all. Flexible circuits 40 providereliable connections that are better able to withstand mechanicalshocks, and the flexible circuits 40 are able to provide a more compactdesign.

The manufacturing of the embodiment 10 is also easier using the flexiblecircuit 40 as compared with soldering individual wires which requiremanual manipulation and several soldering tasks.

The electrical storage device 25 has a first end 25 a that generallycorresponds to a positive terminal and a second end 25 b that generallycorresponds to a negative terminal. As can be seen in FIG. 3A, theflexible circuit board 40 has a proximal end 40 p and a distal end 40 d.The positive terminal at the first end 25 a of the electrical storagedevice 25 is in electrical communication with a positive lead 42 nearthe distal end 40 d of the flexible circuit board 40. The negativeterminal at the second end 25 b of the electrical storage device 25 isin electrical communication with a negative lead 44 near the proximalend 40 p of the flexible circuit board 40. The distal end 40 d of theflexible circuit board 40 is in electrical communication with amicroprocessor 30. As shown in FIG. 4, the microprocessor 30 is acommercially available unit that has a sensor and LED light 32incorporated into its design; however, the sensor and light 32 can beseparate components. The microprocessor 30 is configured to process datafrom the pressure sensor, to control the light 32 (if included) on thefirst portion 15, to direct current flow to a vaporizer 34 in the secondportion 20, and to terminate current flow after a preprogrammed amountof time.

The sensor detects when the electronic cigarette 10 is in use (i.e.,when the user draws on the embodiment) and, in response, activates themicroprocessor 30. The sensor can be selected to detect changes inpressure, air flow, or vibration. In a preferred embodiment, the sensoris a mechanical pressure sensor. In this embodiment, the pressure sensoris a switch that allows current flow to the microprocessor in responseto a change in pressure when the user draws on the electronic cigarette10. In another preferred embodiment, the sensor is a digital pressuresensor such that gradations of pressure can be sensed. In thisembodiment, the digital pressure sensor would pulse off and on tomeasure any change in pressure. In the digital embodiment, the sensortakes continuous readings which in turn requires the digital sensor tocontinuously draw current, but the amount is small and overall batterylife would be negligibly affected. The digital sensor allows for adirect measurement of the change in the pressure.

In embodiments featuring a light 32, the microprocessor 30 is inelectrical communication with the light 32. The light 32 serves as anindicator that the electronic cigarette 10 is in use, i.e., the lightwill glow when the user inhales. The intensity of the glow can betailored to the strength of the user's inhale, meaning that a relativelystronger inhale will cause the light 32 to glow brighter, while arelatively weaker inhale will cause the light to glow dimmer. The colorof light emitted from the light 32 can be any color. For instance, thecolor could be orange or red to simulate the glowing ember of a burningcigarette. In other instances, the color is selected specifically toavoid the appearance of a traditional cigarette so as to assuage theconcerns of onlookers about harmful secondhand smoke.

Additionally, the microprocessor 30 includes a timer. Once themicroprocessor 30 is activated by the sensor, the timer initiates. Aftera preprogrammed amount of time, the timer will shut off themicroprocessor 30, which terminates current flow to the vaporizer 34. Inthis way, the dose of vaping liquid is consistent between draws andlimited. In a preferred embodiment, the timer will deactivate themicroprocessor after five seconds; however, longer or shorter timescould also be used. Because the microprocessor 30 operates on a timer,the microprocessor 30 eliminates the requirement to regulate thetemperature of the vaporizer 34 which also eliminates the need tomeasure the temperature of the vaporizer 34.

Returning to FIG. 2, the second portion 20 of the electronic cigarette10 is generally comprised of a vaporizer 34, a liquid reservoir 45, anda mouthpiece 50.

In the embodiment shown in FIG. 5, the vaporizer 34 and liquid reservoir45 are part of a single cartridge wherein the vaporizer 34 isincorporated in a cap 55 for the liquid reservoir 45.

As shown in FIG. 6, the cap 55 is comprised of an intermediate partition60, having a first surface 60 a and a second surface 60 b (shown in FIG.7B). The intermediate partition 60 defines a plurality of transverselyextending apertures 65. The apertures 65 create capillaries from thesecond surface 60 b through the thickness of the intermediate partition60 to the first surface 60 a. The apertures 65 can vary in diameter fromapproximately 1 mm to approximately 4 mm (the diameter of the capillaryaperture will be dictated to a large extent by the viscosity of thefluid—a more viscous fluid can have a larger diameter capillary withoutleaking, while a less viscous fluid will require a smaller diametercapillary). In an embodiment of the present invention, the partition 60is 1 mm thick and has a first outer ring of apertures 65 that are 1.3 mmwide and a central aperture 65 that is 1.5 mm wide.

Generally speaking, the diameters of the capillaries are sufficient tofacilitate passage of the not yet vaporized fluid. Suitable viscositiesof the fluid are below approximately 100 centipoises (cP), preferablybetween 30 and 90 cP and most preferably between 45 and 75 cP. Anembodiment of the invention utilizes a viscosity of approximately 60 cP.

A myriad of means exists to maintain the viscosity of the vaping liquidat the desired below 100 cP point. Inasmuch as the mixture isvolatilized at relatively low temperatures compared to the light offtemperatures of state of the art e-cigarette configurations, vaporpressures of the mixture should be kept to a minimum. As such, thinningagents, having both polar and nonpolar qualities are suitable, and suchagents include alcohols, carboxylic acids, and similar water misciblecompounds containing hydroxyl, carboxyl or carbonyl moieties.

In an embodiment of the invention, ethanol is utilized to maintain theviscosity of the mixture at about 60 cP. The mixture fluid is preheatedto approximately 60° C. and diluted approximately 10 to 60 percent withethanol, preferably between approximately 15 and 30 percent, ethanol andmost preferably about 15-18 percent ethanol. In an embodiment of theinvention, 17 percent ethanol dilution was utilized.

The apertures 65 can be circular or any other of a variety of geometricshapes. As depicted in FIG. 6, the apertures 65 are elliptical or bentellipses. The fluid passageway provided by the aperture establishesfluid communication between the liquid reservoir 45 and the cap 55.

Extending from the first surface 60 a of the partition 60 is a perimeterwall 70. The perimeter wall 70 has tall regions 75 and short regions 80.In the tall regions 75, the height of the perimeter wall 70 is higherthan the height of the short regions 80. Protruding from the mediallyfacing surface of the tall regions 75 of the perimeter wall 70 is aplurality of ridges 85.

Extending from the second surface 60 b of the partition 60 is a plug 90.The plug 90 is defined by a ring wall that is indented from theperiphery of the second surface 60 b. The plug 90 is inserted into theliquid reservoir 45. Preferably, when the plug 90 is inserted in theliquid reservoir 45, the perimeter wall 70 forms a smooth and continuoussurface with the exterior of the liquid reservoir 45.

The perimeter wall 70 and intermediate partition 60 define a cavity. Asdepicted in FIG. 7B, inserted into the cavity and in contact with theintermediate partition 60 is a sponge 95. The sponge 95 absorbs vapingliquid from the liquid reservoir 45 through the apertures 65. The sponge95 is overlaid with a wick 100. The wick 100 transports vaping liquid tothe vaporizer 34 via capillary action. Preferably the wick 100 is afiberglass wick; however, cotton, paper, or other fiber strands could beused for a wick material. In one embodiment of the electronic cigarette,the liquid reservoir 45 contains a flexible bladder that maintainspressure on the vaping liquid in the liquid reservoir. This pressure isbalanced against the surface tension of the liquid at the aperture 65 ofthe capillaries in the partition 60 such that a small change in pressureallows flow but the capillaries do not leak otherwise.

As can be seen in FIG. 7A, a heating element 105 is placed directlyabove the wick 100. As depicted in FIG. 7A, the heating element 105 is acoil, but other heating elements can also be used, such as thin filmsand thick films. In a preferred embodiment, the heating element has apositive temperature coefficient (“PTC”), i.e., the electricalresistance of the heating element 105 increases as the temperatureincreases. In this way, the maximum temperature of the heating elementcannot exceed a material-specific amount because current flow will becut off by the increased electrical resistance. Accordingly, thematerial used for the heating element 105 can be selected to ensure thatthe electronic cigarette 10 operates within a desired temperature range.A desirable temperature range for vaping liquid is typically between100° C. and 300° C. at atmospheric pressure, and an even more desirabletemperature range at which the heating element operates is between 150°C. and 250° C. at atmospheric pressure.

A variety of PTC materials can also be used for the heating element 105.Suitable heating elements for the coil heater include wire nickel-ironalloys on a mica former. Suitable heating elements for the thin film andthick film heaters could be constructed of a carrier of alumina,zirconium oxide, calcium oxide, silicon dioxide, potassium oxide,magnesium oxide, boron carbide, sodium oxide, and combinations thereof.In embodiment of the invention, alumina was the chosen carrier.

Conductor coatings are electrically conductive substrates comprised ofmetals, such as those selected from the group consisting of silver,palladium, gold, copper, aluminum, tungsten, zinc, or alloys thereof;films of nickel, platinum, molybdenum, iron, steel, and alloys thereof;a glaze, such as DuPont overglaze ink; and self-leveling printed epoxycovercoats. The thick film heaters differ from the thin film heaters intwo respects: thickness and deposition technique. The thick film heaterscan be deposited in more ways, such as through printed resistive inks,while the thin films can be sputter coated on a substrate.

When the user draws on the electronic cigarette 10, the vaping liquid isdrawn from the reservoir 45, through the plurality of apertures 65, andinto the sponge 95 and wick 100. The wick 100 brings the vaping liquidinto contact with the heating element 105 of the vaporizer 34. Theuser's draw also causes the sensor to activate the microprocessor 30,which directs current to the heating element 105. Thus, when the userdraws on the mouthpiece 50 of the electronic cigarette 10, two actionshappen simultaneously. First, the sensor activates the microprocessor30, which triggers the heating element 105 to begin heating. Second, thedraw reduces the pressure outside the reservoir 45 such that flow of thevaping liquid through the apertures 65 begins, which saturates thesponge 95. The wick 100 transports the vaping liquid to the heatingelement 105, which vaporizes the liquid. Typically, the heating element105 will achieve a temperature of approximately 230° C. and the vapingliquid will be vaporized by the heating element 105 within 0.5 secondsof the user's first draw.

The heating element 105 is in electrical communication with electricalcontacts 106 a, 106 b. Returning to FIG. 3C, the proximal end 40 p ofthe flexible circuit board 40 has an outer electrode 107 and an innerelectrode 109. The inner electrode 109 contacts the first electricalcontact 106 a, and the outer electrode 107 contacts the secondelectrical contact 106 b. Via the flexible circuit board 40, the firstelectrical contact 106 a is in electrical communication with thepositive terminal of the electrical storage device 25 by way of themicroprocessor 30, while the second electrical contact 106 b is inelectrical communication with the negative terminal of the electricalstorage device 25.

The electrical contacts 106 a, 106 b are embedded in a disc 111. Thedisc 111 is designed to be received inside the perimeter wall 70 of thecap 55. The disc 111 rests on the ridges 85, thereby creating avaporizing chamber 114. The disc 111 can be made using a variety ofthermoplastic materials. Additionally, the disc 111 can be made of FR4,which is commonly used to make printed circuit boards.

Because the perimeter wall 70 is comprised of tall regions 75 and shortregions 80, the combination of the cap 55 and disc 111 creates windows115 in the perimeter wall 70. These windows 115 allow the vapor toescape from the vaporizer 34. The vapor flows out the windows 115,around the exterior of the liquid reservoir 45, and to the mouthpiece50. In a preferred embodiment, the mouthpiece 50 is comprised of adiffuser (not shown) and a vortex outlet 119. The diffuser is a discwith a central aperture that concentrates the vapor into the vortexoutlet 119. The combination of the diffuser and vortex outlet 119control the pressure drop of the electronic cigarette 10 and prevent thewhistling noise associated with the mouthpiece of some conventionalelectronic cigarettes.

Reusable Embodiment

Turning to the reusable embodiment depicted in FIG. 8, the first portion15 and second portion 20 are separate components that can be reversiblyjoined together.

In the reusable embodiment, the components are substantially the same.The differences in the reusable embodiment vis-à-vis the disposableembodiment are the accommodations made to reversibly attach the firstportion 15 and second portion 20 (often with reusable electroniccigarettes the second portion 20 is referred to as a “cartomizer”because it contains the liquid cartridge and vaporizer). The firstportion 15 has a distal end 15 d and a proximal end 15 p, and the secondportion 20 has a distal end 20 d and a proximal end 20 p. In thereusable embodiment, the first portion 15 and second portion 20 arereversibly attachable, such that the proximal end 15 p of the firstportion 15 is attached to the distal end 20 d of the second portion 20.A variety of suitable connections can join the first portion 15 to thesecond portion 20, including magnetic joints, snap lock joints, and pinand groove joints, among others. In a preferred embodiment, which isdescribed in the following, the first portion 15 and second portion 25are joined using a threaded connection.

Because the electrical storage device 25 is located in the first portion15 and the vaporizer 34 is located in the second portion 15, the jointneeds to provide electrical communication between those components. Inthe present invention, electrical communication is established usingelectrodes that are compressed together when the first portion 15 istightened into the second portion 20. As depicted in FIG. 8, the firstportion 15 has a male threaded end 125 that is adapted to be received bya female threaded end 127 on the second portion 20. The male threadedend 125 and the female threaded end 127 have interior cavities that areadapted to receive the components that provide electrical communicationbetween the first portion 15 and the second portion 20.

Electrical communication is established by compressing electrodes in thefirst portion 15 to electrodes in the second portion 20. As can be seenin FIG. 9, the first portion 15 contains a central pin electrode 130 a,second portion 20 contains a central pin 130 b. The central pins eachhave broad, flat heads 132 a, 132 b that contact each other. The shafts134 a of the central pin 130 a of the first portion 15 contacts theinner electrode 109 on the proximal end 40 p of the flexible circuit 40.The shaft 134 b of the central pin 130 b of the second portion 20contacts the first electrical contact 106 a connected to the heatingelement 105. FIG. 10 shows an exploded view of the electrode assemblies.Referring to FIG. 10, surrounding the central pins 130 a, 130 b areinsulating sheaths 136 a, 136 b. The sheaths 136 a, 136 b are insertedinto washers 138 a, 138 b. The washer 138 a is in electricalcommunication with the outer electrode 107 on the proximal end 40 p ofthe flexible circuit 40, while the washer 138 b is in electricalcommunication with the second electrical contact 106 b that is connectedto the heating element 105. The sheaths 136 a, 136 b prevent the centralpins 130 a, 130 b from contacting the washers 138 a, 138 b and shortingout the connections. The washers 138 a, 138 b are in electricalcommunication with the threads of the male threaded end 125 and thefemale threaded end 127, respectively, such that, when the first portion15 and second portion 20 are joined, electrical communication isestablished between the first portion 15 and the second portion 20.

In order for this embodiment to be reusable, the electrical storagedevice 25 is rechargeable. In a preferred embodiment, the electricalstorage device is a rechargeable 3.7V lithium-ion battery. In order tocharge the electrical storage device 25, a variety of charging optionsexist, including charging cables and inductive charging. In a preferredembodiment, the electrical storage device is charged by inserted thefirst portion 15 into a charging case. The charging case contains acharging receptacle that features a reversible joint complementary tothat of the first portion. The case is connected via cable to a powersource. In one embodiment, the case is charged using a USB cable thatcan be plugged into a wall adapter. In another embodiment, the USB cableis plugged into a computer port.

Besides the reversible joint between the first portion 15 and the secondportion 20 and the recharging capability, operation of the reusableembodiment is similar to the disposable embodiment. One benefit of thereusable embodiment is that the second portion 20, or cartomizer, isreplaceable, so the user can change vaping liquids.

Dosage Control Embodiment

In another embodiment of the presently invented electronic cigarette 10,the dose of vaping liquid is controlled by the microprocessor, such thata user-programmable dose of vaping liquid is administered in each draw.

In this second embodiment, the electronic cigarette 10 contains manysimilar features as in the previous embodiment, including an electricalstorage device 25, a microprocessor 30, an optional light 32, avaporizer 234, a liquid reservoir 245, and a mouthpiece 50.

As in the previous embodiment and as shown in FIG. 11, the vaporizer 234is contained in a cap 255. The cap 255 has an intermediate partition 260that defines a first aperture 265. Extending from a first surface 260 aof the partition 260 is a perimeter wall 270, having tall regions 275and short regions 280. Extending from a second surface 260 b of thepartition 260 is a plug 281 that allows the cap 255 to be inserted intothe liquid reservoir 245. The plug 281 is defined by a ring wall that isindented from the periphery of the second surface 260 b. When the cap255 is inserted into the liquid reservoir 245, the perimeter wall 270preferably creates a smooth and continuous surface with the exterior ofthe liquid reservoir 245. Protruding from the medially facing surface ofthe perimeter wall 270 are ridges 285. The ridges 285 support a disc287, containing electrical contacts 289 a, 289 b. The combination of thedisc 287 and the short regions 280 of perimeter wall 270 define windows292 in the cap 255. Disposed between and in electrical communicationwith the electrical contacts 289 a, 298 b is a heating element 290. Theheating element 290 can be selected from a variety of suitable heatingelement types, including coils, thin films, and thick films. The heatingelement material is preferably selected from the heating elementmaterials mentioned in the previous embodiments.

The dosage control embodiment operates in one of two ways. The firstdosage control embodiment uses a heat pump to dispense vaping liquidfrom the reservoir. The second dosage control embodiment uses adiaphragm pump to dispense vaping liquid. Both embodiments use the samecap 255 discussed above; however, the components formed or inserted intothe cap will vary.

In the heat pump embodiment depicted in FIG. 12, the first surface 260 aof the partition is overlaid with a substrate 295. A film 300 is placedover or deposited on the substrate 295. The film 300 is a second heatingelement and the materials for the film can be selected from the samematerials as the heating element 290. The substrate 295 is preferably asilicon wafer with tracers embedded in it to carry current from thebattery to the film 300. Formed through the thickness of the film 300and substrate 295 is a second aperture 305 that lies in registrationwith the first aperture 265 in the intermediate partition 260. Aninverted cup 310, having sidewalls 315 and a flat superior end 320, isplaced over the film 300. The sidewalls 315 and flat superior end 320define a heating region 325. The flat superior end 320 features a nozzle330 having a depending capillary channel 331 that creates a fluidpassageway from the heating region 325 (and thus, the liquid reservoir245 by way of the first and second apertures 265, 305) and the exteriorof the inverted cup 310.

When the user draws on the electronic cigarette 10, the microprocessordirects current to the heating element 290 and the film 300. The heatfrom film 300 causes a vapor bubble 332 to form in the capillary channel331. As the vaping liquid continues to be heated, the vapor bubble 332will pop, which ejects vaping fluid out of the nozzle 330 and onto theheating element 290 where it is vaporized. The vaporized liquid thenexits from the vaporizer 234 through the windows 292. In the embodimentshown in FIG. 12, the cap 255 has a single aperture 265, heating region325, and a single nozzle 330 with a single capillary channel 331, butthe cap 255 could contain a plurality of heat pumps defined by thoseelements. Preferably, the cap 255 contains five or six heat pumps;although, more or less heat pumps could be included.

The heating region 325 is replenished with vaping liquid after the vaporbubble 332 bursts. Upon bursting, a vacuum is left behind in the regionformerly occupied by the vapor bubble. The difference in pressure causesvaping liquid to flow into the heater region 325 so that a new vaporbubble 332 can form.

The film 300 is not heated to the same temperature as the heatingelement 290. Generally, the film 300 is heated to a maximum temperatureof approximately 150° C. The heating element 290 will be heated to amaximum temperature of 300° C.

In the diaphragm pump embodiment shown in FIGS. 13A-B, the inverted cup310 is placed over the substrate 295, creating a primer region 334.Embedded in the substrate 295 is a region defining a diaphragm 335. Apiezoelectric transducer 340 is placed over the diaphragm 335. Whencurrent is supplied to the piezoelectric transducer 340, thepiezoelectric transducer 340 will reversibly deform, causing thediaphragm 335 to deflect inwardly and outwardly. When the diaphragm 335deflects inwardly as shown in FIG. 13A, the volume of the primer region334 is decreased, which causes vaping liquid to be forced into thecapillary channel 331 and ejected out of the nozzle 330 onto the heatingelement 290. When the diaphragm 335 deflects outwardly as shown in FIG.13B, it draws more vaping liquid into the primer region 334. As inprevious embodiments, when the vaping liquid contacts the heatingelement 290, it vaporizes and exits the vaporizer through the windows292. Like in the heat pump embodiment, the diaphragm embodiment cancontain a multitude of diaphragm pumps within the cap 255. Preferably,the cap 255 will contain 5 or 6 diaphragm pumps; although, more or lesspumps can be included.

In both the heat and diaphragm pump embodiments, the vapor travelsoutside the reservoir 245 to the mouthpiece 50. As in the previousembodiments, the mouthpiece can contain a diffuser and a vortex outlet350 as described in the previous embodiment.

In the dosage control embodiment, the microprocessor 30 performs many ofthe same functions as the microprocessor 30 of the previous embodiment,including, controlling the light 32, processing data from the sensor,and controlling current to the vaporizer 234. In this embodiment,though, the microprocessor 30 uses pulse width modulation to deliverpulses of current to the film 300 and the piezoelectric transducer 340and to the heating element 290. Using pulsed current provides bettertemperature control of the film 300 and heating element 290 and allowsfiner tuning of the dosing of the piezoelectric transducer 340. Themicroprocessor 30 also runs on a timer, as in the previous embodiments,but, besides controlling current to the heating element 290, the timeralso controls the amount of vaping fluid delivered by the heat ordiaphragm pump and the maximum draw length (as selected by the user).Additionally, in some embodiments, the microprocessor 30 can communicatewith outside equipment, such as applications or computers.

In the dosage control embodiment, the dosage of liquid delivered can bestrictly controlled by the microprocessor 30 because the amount ofliquid delivered can be precisely tuned using the heat or diaphragmpump. In this way, the user can set the dosage for each pump and themaximum dosage for a given period of time. The dosage can be set in avariety of suitable ways, including dials or buttons on the exterior ofthe electronic cigarette 10. If dials are used, the user would rotate orswivel a component of the electronic cigarette to select the dose from acontinuous range of doses. If buttons are used, then the user woulddepress the button associated with the preselected dosage amounts. In apreferred embodiment, the dose is controlled wirelessly using, forinstance, an application in communication with the electronic cigaretteover Bluetooth or Wi-Fi.

This embodiment has particular applicability for those who useelectronic cigarettes as a means to quit smoking and reduce theirnicotine dependency. The electronic cigarette 10 provides a way togradually taper the dose of nicotine, not only in each draw but also thedaily amount.

Other embodiments of the invented electronic vaporization inhaler areeasily envisioned, including medicinal delivery devices and atomizers.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from its scope. While the dimensions and types ofmaterials described herein are intended to define the parameters of theinvention, they are by no means limiting, but are instead exemplaryembodiments. Many other embodiments will be apparent to those of skillin the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the terms“comprising” and “wherein.” Moreover, in the following claims, the terms“first,” “second,” and “third,” are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112(f) unless and until such claim limitations expresslyuse the phrase “means for” followed by a statement of function void offurther structure.

As will be understood by one skilled in the art, for any and allpurposes, particularly in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” “more than”and the like include the number recited and refer to ranges which can besubsequently broken down into subranges as discussed above. In the samemanner, all ratios disclosed herein also include all subratios fallingwithin the broader ratio.

One skilled in the art will also readily recognize that where membersare grouped together in a common manner, such as in a Markush group, thepresent invention encompasses not only the entire group listed as awhole, but each member of the group individually and all possiblesubgroups of the main group. Accordingly, for all purposes, the presentinvention encompasses not only the main group, but also the main groupabsent one or more of the group members. The present invention alsoenvisages the explicit exclusion of one or more of any of the groupmembers in the claimed invention.

Numerous modifications to the present invention will be apparent tothose skilled in the art in view of the foregoing description. It is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention. Accordingly, this description is to be construed asillustrative only of the principles of the invention and is presentedfor the purpose of enabling those skilled in the art to make and use theinvention and to teach the best mode of carrying out same. The exclusiverights to all modifications which come within the scope of the appendedclaims are reserved. All patents, patent publications and applications,and other references cited herein are incorporated by reference hereinin their entirety.

We claim:
 1. An electronic vaporizing inhaler, comprising: an electricalstorage device; a flexible circuit board; a liquid reservoir adapted toreceive vaping liquid; and a vaporizer: wherein the electrical storagedevice is disposed in electrical communication with the flexible circuitboard, and wherein the flexible circuit board comprises an elongatestrip of a flexible material having a proximal end and a distal end; aninner electrode and an outer electrode disposed on the proximal end; anda microprocessor disposed in electrical communication with the distalend; wherein the elongate strip provides electrical communicationbetween the proximal end and the distal end; wherein the electronicvaporizing inhaler further comprises a housing wherein the housing istwo separable pieces, wherein the electrical storage device and theflexible circuit board are contained in a first piece and the vaporizerand the liquid reservoir are contained in a second piece; wherein a flapof the flexible material extends transversely from the proximal end,wherein the inner electrode is disposed over a center portion of theflap and the outer electrode is disposed around a perimeter of the flap,and wherein the electronic vaporizing inhaler further comprises a firstpin electrode disposed within the first piece and in electricalcommunication with the inner electrode; and a second pin electrodedisposed within the second piece and in electrical communication with afirst electrical contact of a heating element disposed in the vaporizer;wherein facing ends of the first and second pin electrodes comprise flatheads that make electrical contact with each other when the first pieceis engaged with the second piece.
 2. The electronic vaporizing inhalerof claim 1, wherein the vaporizer comprises a heating element disposedin electrical communication with first and second electrical contacts,and wherein the inner electrode engages with the first electricalcontact and the outer electrode engages with the second electricalcontact.
 3. The electronic vaporizing inhaler of claim 2, wherein theflexible circuit board is configured to electrically connect the firstelectrical contact to a first terminal of the electrical storage device,and to electrically connect the second electrical contact to a secondterminal of the electrical storage device.
 4. The electronic vaporizinginhaler of claim 3, wherein at least one of the connections between thefirst electrical contact and the first terminal of the electricalstorage device and the second electrical contact and the second terminalof the electrical storage device is by way of the microprocessor.
 5. Theelectronic vaporizing inhaler of claim 1, wherein the distal end of theflexible circuit board further supports and provides electricalcommunication for at least one of a pressure sensor and a light, whereinthe at least one of a pressure sensor and a light is disposed inelectrical communication with the microprocessor.
 6. The electronicvaporizing inhaler of claim 1, wherein the first pin electrode issurrounded by a first insulating sheath that is in turn surrounded by afirst washer, and the second pin electrode is surrounded by a secondinsulating sheath that is in turn surrounded by a second washer, wherethe first washer is disposed in electrical communication with the outerelectrode in the first piece, and the second washer is disposed inelectrical communication with a second electrical contact of the heatingelement disposed in the vaporizer in the second piece.
 7. The electronicvaporizing inhaler of claim 6, wherein the first washer is disposed inelectrical communication with threads of a first threaded end of thefirst piece, and the second washer is disposed in electricalcommunication with threads of a second threaded end of the second piecesuch that when the first piece and the second piece are joinedelectrical communication is established between the outer electrode andthe second electrical contact of the heating element.